Modbus RTU Over RS-485: A Detailed Explanation

Modbus RTU (Remote Terminal Unit) over RS-485 is a popular industrial protocol used for
communication between devices like Programmable Logic Controllers (PLCs), Remote Terminal Units
(RTUs), Intelligent Electronic Devices (IEDs), sensors, and actuators. It combines the Modbus RTU
protocol with the RS-485 physical layer to enable robust, long-distance, and multi-device
communication.

Key Features of Modbus RTU over RS-485

1. Protocol: Modbus RTU

o A simple, open, and widely used communication protocol.

o Data is transmitted in binary form (compact and efficient).

o Uses a master-slave architecture:

 Master: Initiates queries (e.g., RTU, PLC, or SCADA system).

 Slave(s): Responds to the queries (e.g., sensors, IEDs, actuators).

2. Physical Layer: RS-485

o A multi-drop, half-duplex communication standard.

o Supports up to 32 devices (masters and slaves) on a single bus.

o Uses differential signaling, which reduces noise and supports long-distance

communication (up to 1200 meters).

3. Communication Medium

o Two-wire or four-wire twisted-pair cabling.

o Two-wire setup is more common for Modbus RTU over RS-485.

How It Works

Master-Slave Communication

 Master sends a query to one or more slaves.

 Each slave device listens to the bus and responds only if addressed.

 Only one device communicates on the bus at a time (avoiding data collisions).

Message Frame Structure

1. Address Field (1 byte)

o Identifies the target slave (range: 1-247). Address 0 is for broadcast.

2. Function Code (1 byte)

o Specifies the action (e.g., read/write data).

 o Common codes:

 03: Read Holding Registers

 06: Write Single Register

 16: Write Multiple Registers

3. Data Field (Variable)

o Contains the details of the query or response (e.g., register addresses, values).

4. Error Checking (CRC - 2 bytes)

o Cyclic Redundancy Check ensures data integrity.

RS-485 Electrical Signaling

 Differential signaling uses two wires:

o A (Data-) and B (Data+).

 Devices on the RS-485 bus listen for voltage differences:

o Positive difference → Logic 1

o Negative difference → Logic 0

Example of Modbus RTU Over RS-485

Scenario

 Master: SCADA system in a substation.

 Slaves:

o IED 1: Measures voltage.

o IED 2: Measures current.

o IED 3: Controls a circuit breaker.

Wiring

 Two-wire RS-485 bus:

o A (Data-) and B (Data+): Connect all devices in parallel.

o Ground: Optional but recommended for noise immunity.

Master Query

 Address: 02 (IED 2)

 Function Code: 03 (Read Holding Registers)

 Data: Start Register 0001, Number of Registers 0002.

 CRC: Automatically calculated and appended.

Message Frame Sent by the Master:

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[02] [03] [00 01] [00 02] [CRC]

Slave Response (IED 2):

 Address: 02

 Function Code: 03

 Data: Register 1 = 12.34 A, Register 2 = 56.78 A.

Message Frame from Slave:

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[02] [03] [04] [12 34 56 78] [CRC]

Advantages of Modbus RTU Over RS-485

1. Cost-Effective: Simple wiring and no licensing fees.

2. Long Distance: RS-485 supports up to 1200 meters.

3. Multi-Drop Capability: Connect up to 32 devices on a single bus.

4. Noise Immunity: Differential signaling reduces interference.

Applications

1. Substations: Communication between RTUs, IEDs, and SCADA systems.

2. Industrial Automation: Interfacing PLCs with field devices like sensors and actuators.

3. Building Automation: HVAC systems, lighting control, and energy monitoring.

Limitations

1. Speed: Typically limited to 10 Mbps, sufficient for most industrial applications but slower
than Ethernet.

2. Polling-Based: Master must poll slaves, potentially increasing latency.

3. Limited Device Count: RS-485 supports only up to 32 devices (expandable with repeaters).

Practical Example
  Substation Use Case:

o A SCADA master polls a circuit breaker IED to check its status (open or closed) and
logs voltage and current measurements.

o The RS-485 bus connects multiple IEDs to a central RTU using a two-wire twisted-
pair cable.

o Modbus RTU ensures efficient and reliable data exchange, even in noisy
environments.

This robust system is widely used in power systems and industrial setups to ensure seamless, long-
distance, and reliable communication.

MODBUS TCP/IP: Overview and Explanation

MODBUS TCP/IP is an industrial communication protocol that operates over TCP/IP networks. It is
widely used in industrial automation systems to enable communication between devices such as
PLCs (Programmable Logic Controllers), sensors, and SCADA (Supervisory Control and Data
Acquisition) systems.

Key Features of MODBUS TCP/IP

1. Protocol Type:

o Application layer protocol based on the TCP/IP stack.

o Enables communication over Ethernet networks.

2. Communication Architecture:

o Follows a client-server model.

 Client (Master): Initiates communication (e.g., SCADA system).

 Server (Slave): Responds to requests (e.g., a PLC or sensor).

3. Supported Data Types:

o Coils: Discrete outputs (1-bit).

o Discrete Inputs: Discrete inputs (1-bit).

o Input Registers: Analog inputs (16-bit).

o Holding Registers: Analog outputs or configuration parameters (16-bit).

4. Port:

o Uses TCP port 502 by default for communication.

5. Reliability:

o Built-in error checking provided by TCP/IP layers ensures data integrity.

How MODBUS TCP/IP Works

1. Request-Response Cycle:

o The client sends a MODBUS request (e.g., read or write data).

o The server processes the request and sends a response back to the client.

2. Message Format:

o Header: Contains TCP/IP information such as transaction ID, protocol ID, and
message length.

o Function Code: Specifies the operation (e.g., read/write).

o Data Field: Contains the data or parameters for the operation.

Example Use Case

Scenario:

A factory's SCADA system needs to monitor the temperature of an industrial furnace controlled by a
PLC.

1. Setup:

o The temperature sensor is connected to the PLC.

o The PLC communicates with the SCADA system over Ethernet using MODBUS TCP/IP.

2. Communication Steps:

o SCADA System (Client): Sends a request to the PLC (Server) to read the temperature
value stored in a holding register.

 Request Message:

 Function Code: 0x03 (Read Holding Register).

 Register Address: 40001 (address of the temperature value).

o PLC (Server): Responds with the value from the specified register (e.g., 450
representing 45.0°C).

3. Real-Time Monitoring:

o The SCADA system continuously polls the PLC to update the furnace temperature in
real-time.

Key Benefits of MODBUS TCP/IP

1. Wide Compatibility:

o Supported by a wide range of devices from various manufacturers.

2. Scalability:
 o Easily integrates with large Ethernet-based networks.

3. Interoperability:

o Allows devices from different vendors to communicate seamlessly.

4. Ease of Use:

o Simple message structure and minimal configuration required.

Advanced Example

Energy Monitoring System

1. System Components:

o Energy Meter (Server): Measures power consumption.

o SCADA System (Client): Monitors energy usage.

2. Workflow:

o The SCADA system sends a MODBUS request to read real-time energy usage from
holding registers in the energy meter.

o The energy meter responds with the consumption data (e.g., 10,500 kWh).

o SCADA displays the data on dashboards for operators.

Comparison: MODBUS TCP/IP vs MODBUS RTU

Feature MODBUS TCP/IP MODBUS RTU

Communication Medium Ethernet (TCP/IP network) Serial (RS-232/RS-485)

Speed High Moderate

Topology Flexible (LAN/WAN) Point-to-point or multipoint

Ease of Deployment Requires Ethernet infrastructure Requires serial cabling

Conclusion

MODBUS TCP/IP is a robust, reliable protocol for modern industrial systems, enabling efficient
communication over Ethernet networks. Its compatibility, scalability, and ease of implementation
make it a preferred choice in industries like manufacturing, energy, and utilities.